Lighting retrofit: plan it properly.
Successful warehouse lighting retrofits start with energy audit, photometric design, controls strategy, and phased install plan that minimizes operational disruption.
By Steven Lockhart · Reviewed by Alex Towery, C-10 #989290
Updated 2026-06-16
Lighting retrofit project scope: pre-retrofit audit (existing fixture count, wattage, operating hours, energy consumption), photometric design (fixture selection and layout for target footcandles), controls strategy (sensors, dimming, scheduling), install plan (phases, sequencing, operational accommodations), rebate application, commissioning and verification. Marin commercial projects 50-500+ fixtures, $20,000-$200,000+ total scope. We handle full project lifecycle.
01Why retrofit planning matters.
Lighting retrofits can be done badly — just swap fixtures and call it done — but proper planning yields significantly better outcomes: photometric design ensures adequate light levels (under-lit warehouses are workplace safety issues), controls strategy maximizes energy savings (often 30-50% beyond LED savings alone), phased install minimizes operational disruption, rebate application captures available utility incentives. The difference between hasty retrofit and planned retrofit can be 25-40% in lifetime value.
Pre-retrofit audit establishes the baseline. We measure existing footcandle levels at task surfaces (NEC and OSHA don't dictate; industry standard is 30fc minimum for warehouse general areas, 50fc+ for inspection and detail work areas). Compare against target. Identify any dark spots or over-lit areas. Document existing fixture count, wattage, and operating hours. Energy consumption baseline establishes ROI calculation foundation.
02Project phases.
Phase 1: audit and design
Site visit, measurement, photometric analysis, fixture and controls selection, draft design, ROI calculation. 1-3 weeks. Often paid as professional services or rolled into project quote.
Phase 2: pre-install
Permit pull, equipment procurement (LED fixtures have 4-8 week lead time typical), rebate application submission, schedule coordination with operations. 4-10 weeks parallel.
Phase 3: install
Phased install zone by zone. Typically 10-25 fixtures per day depending on access. Total install time 2-6 weeks for typical Marin warehouse depending on size.
Phase 4: commissioning
Verify all fixtures operational, controls configured per design, measure post-retrofit footcandles, document for rebate completion, train facility staff on controls.
03Controls and Title 24.
California Title 24 requires automatic lighting controls in commercial spaces: occupancy sensors in most spaces, daylight controls in spaces with significant daylight, multilevel switching, demand response capability. New construction and major retrofits must comply. Existing buildings doing partial retrofit have some grandfathering, but lighting changes triggering Title 24 compliance are common. We design to Title 24 from the start.
Beyond compliance, smart controls deliver meaningful additional savings. A warehouse running 12 hours daily with motion sensors keeping aisles at 10% when unoccupied can reduce lighting energy 30-50% beyond LED-only savings. Modest cost adder for controls integration; significant ongoing savings. Most Marin warehouse retrofits include integrated motion sensing as default; daylight sensing where skylights or windows justify.
Common questions.
How accurate are photometric design predictions?
Modern photometric software (AGi32, Dialux, Visual) is accurate within 5-10% of actual measured footcandles when input data is correct (fixture photometric files, room dimensions, surface reflectances). We use validated software and verify reflectance values at site visit. Post-install measurement typically matches design within 10%. If significant discrepancy, we troubleshoot (fixture orientation, controls settings) until design intent is achieved.
How do you minimize operational disruption?
Strategies: night/weekend install for live-operation warehouses, zone-by-zone phasing to limit impact area, temporary lighting if needed during fixture swap, scheduling around shift changes and operational peaks. Pre-install meeting establishes operational constraints and works backward to install plan. Most Marin warehouse retrofits complete with zero operational shutdown — just localized inconvenience during work hours.
What rebates are available?
PG&E commercial lighting rebates for LED retrofits — current programs include calculated rebates (based on baseline-to-LED kWh savings) and prescriptive rebates (set amount per fixture type). Programs change annually; current rebates typically $50-$200 per fixture for high-bay LED retrofit. Application submitted post-install with documentation; rebate check typically 2-4 months later. Reduces project net cost 10-25%.
What's typical ROI for warehouse LED retrofit?
Most Marin warehouse retrofits show 18-36 month payback from energy savings alone, with longer-term savings from reduced lamp/ballast replacement and labor. Lighting consumes 20-40% of typical warehouse electricity; LED retrofit cuts that 50-70%. For a warehouse spending $30,000/year on lighting electricity, retrofit savings of $18,000/year on $40,000 project = 2.2 year payback. Each warehouse situation varies; we calculate site-specific ROI during planning.
How do you handle pricing — flat fee or hourly?
Both, depending on scope. Routine service calls and predictable scope (panel replacement, EV charger install, transfer switch install, fixture replacement) are flat-fee quoted up front. Diagnostic visits and emergency scope are hourly because we don't know what we'll find. Either way, you get a written quote before work starts on anything significant, and we don't proceed beyond the quote without your sign-off.
How quickly can you schedule?
Depends on scope and season. Emergency dispatch: same-day across Marin County (1-3 hours business hours, 1-4 hours after-hours). Same-day standard service: 3-6 hours from call when capacity allows; otherwise next business day. Scheduled service work: 1-3 weeks typical. Larger projects requiring permits and PG&E coordination: 4-12 weeks depending on scope. We're upfront about timeline at the quote stage.
What warranty do you offer on work?
Our standard residential warranty: 2 years on labor, manufacturer warranty on parts (varies by product — typically 1-10 years). Major installs (panels, generators, EV chargers) often have longer manufacturer warranties (5-10 years). If there's an issue with our work in the warranty period, we come back and fix it at no cost. We also stand behind work past warranty — repeat customers and referrals matter more than a transactional fix.
Are you licensed and insured?
Yes. California State License Board C-10 Electrical Contractor #989290, in good standing. Carry general liability insurance and workers' compensation insurance as required by California law. Bondable on projects requiring it. Happy to provide proof of insurance to clients or property managers on request. License lookup: cslb.ca.gov.
Schedule a consult before storm season.
Best window for prep work: October before Marin's atmospheric-river season starts. Beat the rush, lock pricing.